Mega 120E Pump Manual

SERIAL NUMBER (located on top of product): PATENTS: U.S. 09642426, U.S. 06106246, U.S. 05971402, U.S. 05370507 11/72019 – M120E-A

Phone: 800-669-1303 or 801-561-0303 Fax: 801-255-2312 E-mail: [email protected]

Mega 120E PUMP Operation / Maintenance Manual

MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL CONTENTS

CONTENTS

1 INSTALLATION ............................................................................................................ 3 1.1 UNPACKING ...................................................................................................... 3 1.2 TIE BOLT TORQUE ........................................................................................... 3 1.3 UTILITIES / HOOK-UP ....................................................................................... 3

2 OPTIONS ...................................................................................................................... 6 2.1 FLUID PORT CONNECTION OPTIONS ............................................................ 6 2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP .................................... 6 2.3 OPTIONAL LEAK SENSING .............................................................................. 7

2.3.a Installation .............................................................................................. 7 2.3.b Removal ................................................................................................. 7 2.3.c Sensor Signal Specifications ................................................................. 8

3 START-UP .................................................................................................................... 9 3.1 HIGH TEMPERATURE OPERATION ................................................................ 9 3.2 PERFORMANCE CHARTS ................................................................................ 9

4 MAINTENANCE .......................................................................................................... 11 4.1 PREVENTIVE MAINTENANCE SCHEDULE ................................................... 11

4.1.a Preventive Maintenance Record ......................................................... 13 4.2 RECOMMENDED SPARE PARTS .................................................................. 14 4.3 TOOLS .............................................................................................................. 14 4.4 PARTS ILLUSTRATION ................................................................................... 15 4.5 PARTS LIST ..................................................................................................... 16 4.6 CLEAN-UP ........................................................................................................ 16 4.7 DISASSEMBLY ................................................................................................ 16

4.7.a Quick Exhaust/Muffler Disassembly .................................................... 17 4.7.b Body Disassembly ............................................................................... 17

4.8 ASSEMBLY ...................................................................................................... 17 4.8.a Quick Exhaust (Both Heads) ............................................................... 17 4.8.b Body Assembly .................................................................................... 18 4.8.c Final Assembly .................................................................................... 21

4.9 TESTING .......................................................................................................... 22 4.9.a Performance Test ................................................................................ 22 4.9.b Dry Pump ............................................................................................. 22 4.9.c Dry Suction .......................................................................................... 22

5 TROUBLESHOOTING ................................................................................................ 23 6 WARRANTY AND EXCLUSIONS .............................................................................. 24

6.1 TREBOR STANDARD LIMITED WARRANTY ................................................. 24 7 CONTACT INFORMATION ........................................................................................ 25

7.1 GENERAL CONTACT INFORMATION ERROR! BOOKMARK NOT DEFINED. 7.2 TECHNICAL SUPPORT ....................... ERROR! BOOKMARK NOT DEFINED. 7.3 REGIONAL REPRESENTATIVES ....... ERROR! BOOKMARK NOT DEFINED.

MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL PAGE 3

1 INSTALLATION 1.1 UNPACKING

After unpacking, the pump should be checked for any damage that may have occurred during shipment. Damage should be reported to the carrier immediately. The following items should be included within the shipping container:

Qty Item Description 1 120E Mega 120E Pump 1 M120E Operation/Maintenance Manual

1.2 TIE BOLT TORQUE The tie bolts on the pump are tightened before leaving the factory. However, relaxation may occur due to handling, material creep, or other unforeseen events. Trebor recommends that all eight tie bolts be re-tightened upon pump install. The following procedure should be used:

1. Remove black tie bolt caps (Item 17 in Figure 4-1) from both sides of all 8 tie bolts6

2. Apply 80 in-lbs. (9.0 N-m) of torque to each slave side bolt while holding the master side bolt stationary. A star-pattern is advised.

a. The master side is the left side of the pump if you are looking at the fluid ports.

3. Replace the tie bolt caps.

1.3 UTILITIES / HOOK-UP The pump is mounted using four 1/4” bolts. It is recommended that the pump be mounted not more than 15° from level to maintain its self-priming ability and pumping efficiency. Air Inlet: 3/8” FNPT (3/8” Dia. [8mm] supply tube minimum). Air Supply: 25-80 psig (0.17-0.55 MPa) clean dry air or nitrogen. (For Air

Consumption, See 3.2 Performance Charts) Fluid Ports: Inlet/Outlet Fluid Fittings and Surge Suppressor require tightening to

specified torque values during pump installation. See section 2.2 for installation diagram and torque values.

Remote Exhaust: 3/8” FNPT (3/8” Dia. minimum tube up to 6’ length, 1/2” Dia. Minimum

tube greater than 6’ length).

PAGE 4 MEGA 120E PUMP OPERATION / MAINTENANCE MANUAL

Figure 1-1

ATTENTION: The pump should be operated with clean, dry air or nitrogen. Particulate, water and oils in the air supply can damage the pump.


NOTE: 1. It is recommended that a filter be placed on the discharge side of the pump. 2. Although extensive efforts are made to deliver pumps to our customers completely dry, new pumps may contain residual moisture from their final DI water test. Recommended Maximum Operating Levels: Maximum supply CDA/N2 pressure: 80 psig (0.55 MPa) Maximum fluid temperature: 212°F (100°C)


2 OPTIONS 2.1 FLUID PORT CONNECTION OPTIONS

Available Options A. Flare style tube adapter 1 1/4” tube fitting – made of high purity PFA

PVDF flare nuts (standard) PFA flare nuts (optional)

B. Custom fittings Contact Trebor Representative

2.2 FLUID FITTINGS / SURGE SUPPRESSOR HOOK-UP Surge Suppressor Assembled Height: mm (in) SS85 434.9 (17.12) SS95 382.5 (15.06)

Figure 2-1


Figure 2-2

NOTE: See Surge Suppressor Operation Manual for detailed installation instructions.

2.3 OPTIONAL LEAK SENSING 2.3.a Installation

• Remove 3/8 NPT plug from port.

• Install 3/8 NPT leak probe fitting into port. See Figure 2-3 for illustration.

• Install probe assembly into fitting. Probe is self-sealing and does not require a seal.

• Tighten nut hand-tight.

• Connect fiber optic cable to sensor (NOTE: Minimize bends in fiber optic cable to 2” radius minimum to help ensure optimum signal strength.). Fiber optic cable can be cut to desired length using the cable cutter provided.

2.3.b Removal • Remove nut from fitting.

• Remove probe.


2.3.c Sensor Signal Specifications • The sensor signal is normally closed. In the event of a leak, no light signal is

returned to the sensor.

NOTE: See your fiber optic sensor installation instructions for proper hook-up and adjustment.

Figure 2-3


3 START-UP • Pump air supply pressure should be regulated.

• Open the fluid suction (IN) line valve, if necessary.

• Open the fluid discharge (OUT) line valve, if necessary.

• Start with air regulator at low pressure setting (<15 psig). Increase or decrease air pressure to attain desired flow, up to 80 psig (0.55 MPa).

• Refer to Troubleshooting, Section 5, if pump fails to start.

ATTENTION: Prolonged periods of dry running (>5 minutes) will damage critical internal pump parts.

CAUTION: When handling potentially dangerous fluids under pressure, the pump and its fittings should be placed in an enclosure.

3.1 HIGH TEMPERATURE OPERATION Pump operation at temperatures above 60°C requires periodic tightening of the tie bolt nuts. The frequency of this procedure is best established by the user.

3.2 PERFORMANCE CHARTS Pumping capacity is a function of air supply pressure and volume, suction head, suction line restrictions, discharge head, discharge line restriction, and fluid properties. The following data was taken using water at atmospheric temperature and pressure with limited sample sizes. The data is intended to aid in system design and should be used for general reference only.

Figure 3-1


Figure 3-2


4 MAINTENANCE

Trebor pump maintenance can be divided into two categories: air system maintenance and fluid system maintenance. The purpose of air system maintenance is to prevent air system failures such as stalling or erratic cycling. The purpose of fluid system maintenance is to maintain suction and lift capabilities.

Pump Rebuild Service Trebor International provides a factory rebuild service for customers using Trebor products. Trebor will rebuild any standard pump (exclusive of options). Please contact Trebor International Sales Department for current pricing. The fixed rebuild price includes a factory rebuild and parts equivalent to the standard rebuild kit. Each factory rebuild comes with a new one-year warranty. Repairs requiring more extensive part replacements will be quoted prior to proceeding with the pump rebuild. If the pump has exceeded its useful life and cannot be rebuilt, the customer may elect to purchase a new Trebor pump. If the customer chooses not to rebuild or replace the pump, a $150.00 evaluation charge will be required. All returned pumps are to be shipped freight prepaid with a valid Purchase Order for the cost of rebuild service. Please contact Trebor International prior to returning your pump to obtain an RMA Number and Pump Return Data Sheet to ensure proper safety precautions. Each pump will be evaluated and repaired within 5 working days of the receipt of pump at Trebor facility.

4.1 PREVENTIVE MAINTENANCE SCHEDULE The following maintenance schedule is recommended to optimize pump performance and minimize failures. Tie bolt torque should be checked within 30 days of start-up and at periodic intervals thereafter. If the pump is subjected to thermal cycle operation, the tie bolt torque should be checked after the first 3 thermal cycles and periodically thereafter. Certain operating conditions that require more frequent maintenance intervals have been noted. In positive pressure inlet conditions where suction or lift is not required, fluid system maintenance may be extended. However, tie bolt retorque is still recommended. Adhering to the recommended preventative maintenance schedule along with periodic inspection of the pump will ensure continued efficient operation and overall reliable pump performance. It is recommended that the Preventive Maintenance Record (Section 4.1.a) be copied, maintained, and kept with this unit for future reference.


MEGA 120E Maintenance Schedule

Inst

all

30 D

ays

3 M

onth

s

6 M

onth

s

9 M

onth

s

12 M

onth

s

15 M

onth

s

18 M

onth

s

21 M

onth

s

24 M

onth

s

Tie Bolt Torque (80 in-lb.) I I I I I Check Seat Wear Rings R

Shaft Bushing R Shaft (High Suction Applications) R

Shaft R Diaphragms and Main Seal R

Diaphragms and Main Seal (HF) R Diaphragms and Main Seal (ACT 935 &

TMAH) R

Quick Exhaust Seal R Check Balls and O-Rings R Check Balls and O-Rings

(High Suction Applications) R

Exhaust Muffler Media R I=Inspect, R=Replace


4.1.a Preventive Maintenance Record Company Name: _____________________________________________________ Company Address: _____________________________________________________

_____________________________________________________ Product: _________________ Serial Number: ________________ Date: ________ Tech: _____ Notes: ________________________________________

________________________________________ Date: ________ Tech: _____ Notes: ________________________________________

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4.2 RECOMMENDED SPARE PARTS KR120E-00-A Spares Rebuild Kit, which includes: Part No Qty Description

KD120-00-A 1 Diaphragm Kit Includes: (2)

(2) 1900B0023 98001585

Diaphragm Set FKM O-Ring

KM120E-00-A 1 Maintenance Kit Includes: (2)

(2) (2) (2) (2)

1900B0016 98003047 L0119 BL002 BL007

Quick Exhaust Port Quick Exhaust Seal Muffler Assembly Suction Seat Check Port Gasket

98004258 4 PTFE O-ring 98004255 4 PTFE Check Ball L0100 16 Tie Bolt Cap BL002 2 Suction Seat BL007 2 Check Port Gasket BL009 2 Fluid Port Gasket BL012 1 Shaft Bushing L0100 16 Tie Bolt Cap

In critical applications, a spare pump is recommended to minimize potential down time.

4.3 TOOLS The following tool kit is recommended as standard service equipment.

KT120-00-A Tool Kit, which includes: Part No Qty Description

98001230 1 5/32” Allen Wrench 98002136 2 7/16” Nut Driver 98002859 1 7/16” Socket 98003150 1 Tool Case 98003305 1 Drive Handle T0172 1 Check Sleeve Insertion Tool T0173 1 Check Sleeve Removal Tool T0146 1 ¾” Pin Tool T0147 1 1” Pin Tool T0148 1 ½” Pin Tool T0159 1 2” Pin Tool T0144 1 Cleaning Tool T000A0021 1 Shaft Bullet


4.4 PARTS ILLUSTRATION

Figure 4-1


4.5 PARTS LIST ILL NO PART NO QTY DESCRIPTION PM

YEAR # MATERIAL

1 BL006 2 Check Bore Plug PTFE 2 BL007 2 Gasket Seal, Check Port 1 PTFE 3 BL004 2 Discharge Sleeve PTFE 4 98004255 4 Check Ball 1 PTFE 5 98004258 4 O-Ring 1 PTFE 6 BL003 2 Suction Sleeve PTFE 7 BL002 2 Suction Seat PTFE 8 BL001 1 Body PTFE 9 BL012 1 Shaft Bushing 1 PTFE

10 L0195 1 Locking Ring PTFE 11 BL011 1 Main Shaft 2 PFA 12 1900B0070 2 Push Plate PTFE 13 1900B0023 2 Diaphragm Set 1 PFA 14 98001585 2 Main Seal 1 Viton 15 L0185-01 2 Head PP 16 L0184 8 Spacer, Tie Bolt PP 17 BL014 8 Tie Bolt Assembly SS302, PFA 18 L0100 16 Tie Bolt Cap 1 LDPE 19 98003047 2 Quick Exhaust Seal 1 Viton 20 1900B0016 2 Quick Exhaust Port UHMW 21 L0119 2 Assembly, Muffler 1 PP 22 98002243 10 Plug, 3/8 NPT PE 23 98003514 2 Fitting, Air PP

24 L0140 8 Bushing NPRN & EPDM

25 1900A0028-01 8 Tie Bolt Washer SS316 26 98002341 8 Nut, Flange, SS, 1/4 - 20 SS18-8 27 98001418 4 Insert SS18-8 28 BL017 1 Pump Base PP 29 98001093 4 Washer SS18-8 30 98001375 4 Screw SS18-8 31 98001108 4 Cap, Blue LDPE 32 98003755 1 Screw, Lock Ring PTFE 33 98003769 2 Screw, Push Plate PTFE 34 AW073 2 End-of-Stroke Port Plug PTFE

4.6 CLEAN-UP

To help remove potentially dangerous chemicals, the pump can be flushed with DI water or disassembled and thoroughly cleaned. Take all appropriate safety precautions commensurate with the chemical risks of the fluid.

4.7 DISASSEMBLY During the life of the pump it will be necessary to perform certain preventative maintenance procedures to ensure its continued high performance. This section and the next (4.8 Assembly) are provided for the user’s convenience in disassembly and re-assembly in performing these procedures.

• Thoroughly clean/flush the pump using DI water (Refer to Section 4.6).

• Remove tie bolt caps from the slave head.

• Remove nuts from the tie bolts (Slave Head side). Leave tie bolts in place.

• Lay the pump on its side with slave side up.


• Lift off the slave head.

• Remove the main seal and diaphragms.

• Remove the o-rings from the shuttle transfer tube.

• Remove the body assembly.

• Remove the second set of diaphragms and main seal.

• Remove the transfer tube and o-rings from the heads and body.

• Remove the remaining tie bolt caps and tie bolts.

NOTE: All polypropylene and fluoroplastic parts, when disassembled, should be thoroughly washed and be free from chemical residue for handling purposes.

4.7.a Quick Exhaust/Muffler Disassembly • Remove the muffler assembly from each head.

• Remove quick exhaust ports from heads.

• Remove quick exhaust seals.

4.7.b Body Disassembly • Remove check bore plugs using 3/4” pin tool and remove seals.

• Remove sleeves, balls, o-rings and check seat. Do not use excessive force.

• Unthread push plate locking screw and push plate from the one side of the shaft.

• Remove remaining shaft and push plate from body.

• Unthread second locking screw and push plate from shaft.

• Unthread shaft bushing locking screw from body.

• Using 2” pin tool, insert pins in shaft bushing locking ring located in the master head side of chamber and rotate CCW to remove bushing. Then push out bushing from the slave head chamber side.

4.8 ASSEMBLY Prior to beginning assembly, inspect all parts to ensure they are clean and dry. Wear clean, protective gloves.

4.8.a Quick Exhaust (Both Heads) • Insert quick exhaust seal.

• Insert quick exhaust port in each head as shown. Tighten to 15 in-lbs. Do not over tighten.


Figure 4-2

• Install 3 each muffler pads onto muffler spool and insert into exhaust port. Tighten to 40 0in-lbs.

4.8.b Body Assembly NOTE: For easy installation, check sleeves that do not install easily (minimal effort) can be placed in a freezer prior to assembly to assist insertion.

• Insert the suction seat. Press firmly using the check sleeve insertion tool until the suction seat is at the bottom of the check bore.

• Install the o-ring. The o-ring should rest inside the cup shape in the seat.

• Install the check ball. Ensure the o-ring does not become dislodged.

• Insert the suction sleeve. Press firmly using the check sleeve insertion tool until the suction sleeve meets the suction seat.

• Install the o-ring. The o-ring should rest inside the cup shape in the seat.

• Install the check ball. Ensure the o-ring does not become dislodged.

• Install the discharge sleeve. The edge of the non-threaded part of the check bore should be approximately flush with the top of the discharge sleeve.

• See Figure 4-3 for the proper order of check assembly installation.


Figure 4-3

NOTE: The suction sleeves are shorter than the discharge sleeves.

• Insert the gasket seal

• Thread on the check port plug and tighten to 120 in-lbs.

• Repeat process for second check bore.


Figure 4-4

• Install shaft bushing per Figure 4-4.

• Install locking ring until flush with fluid cavity face and resistance is met.

• Tighten until next available notch aligns with locking screw hole, check to assure that the shaft bushing does not move.

• Insert locking screw into hole and tighten until flush with locking ring.

• Thread one push plate onto shaft until push plate bottoms out on shaft shoulder. (See Figure 4-5.)

• Tighten push plate to 48 oz.-in, and then rotate CW until locking screw hole is aligned with the next available hole in shaft. The first push plate can be visually aligned separate from the body.

• Install push plate locking screw. Tighten to 12 oz.-in.


Figure 4-5

• Insert shaft through shaft bore as shown in Figure 4-5. (Use shaft bullet tool to prevent damage to shaft or shaft bushing.)

• Thread on remaining push plate until push plate bottoms out on shaft shoulder.

• The second push plate, while in the pump body, cannot be visually aligned. Tighten push plate to 48 oz.-in, then insert alignment pin into locking screw hole. Rotate push plate CW until locking screw hole is aligned with the next available hole in shaft and alignment pin drops into the shaft hole. Remove alignment pin.

• Install push plate locking screw. Tighten to 12 oz.-in.

4.8.c Final Assembly (See Section 4.4, Parts Illustration, for reference.)

• Insert tie bolts into head (press fit) and lay head flat with tie bolts sticking up.

• Place main seal into the main seal groove in head.

• Install two diaphragms, removing all air from between diaphragms, onto the tie bolts and shuttle transfer tube. Note main seal groove alignment.

• Place body assembly onto tie bolts and head.

• Place remaining two diaphragms onto tie bolts. Note main seal groove alignment.

• Place the main seal O-ring into the formed groove of the diaphragms.

• Flip the head over and insert the tie bolts into the second head. Ensure that the main seal is not dislodged.

• Place all bushings & flat washers onto tie bolt threaded ends.

• Install flange nuts onto tie bolts. Tighten evenly in a star pattern (do not overload one side before applying torque to another as dislodgment of main seal can occur). Final torque is 80 in-lbs.


• Snap in tie bolt caps.

4.9 TESTING 4.9.a Performance Test

• Start with air regulator at low (< 15 psi) pressure setting.

• Pump must prime once pressure is increased

• 60 psig Supply Pressure

• Check for fluid leaks, listen for air leaks, check for irregularity

• Prepare the pump for drying

4.9.b Dry Pump • Connect vacuum hose to discharge line

• Connect purge line to fluid inlet

• 60 psig Supply Pressure

• Cycle pump & vacuum dry by rotating pump side to side for 30 seconds.

• Turn off Air Supply and allow the pump to purge for 5 minutes.

4.9.c Dry Suction • 20 psig Supply Pressure Target

• Record Suction Value

• Target = 10 in-Hg


5 TROUBLESHOOTING Pump Will Not Start, Fails to Operate Cause: Solution: Insufficient air volume. See Performance Charts (3.1) for requirements.

Reference regulator and control valve capacity specifications >1.2 Cv.

Fluid discharge line blocked. Downstream valve closed, filter plugged or other obstruction.

Remove obstruction.

Bubbles in Fluid Discharge Cause: Solution: Leaking fluid inlet fitting. Tighten, or remove and wrap with TFE thread tape prior to

tightening. Replace adapter O-ring. Leaking main seal. Tighten tie bolt nuts to 80 in-lbs. Replace main seals if

damaged. Pump inlet line pressure reached

saturation point (due to high suction requirement).

Increase diameter of suction supply line (reduces restriction). Reduce output flow.

Ruptured (perforated) diaphragm. Replace diaphragms.

Fluid Leaks Cause: Solution: Tie bolt torque not enough to effect

seal. Tighten all nuts to 80 in-lbs.

Damaged main seal. Replace. Check for irregularities in diaphragm groove on pump body.

Check bore cap. Tighten, or remove and replace seal. Ruptured diaphragm(s) can result in

fluid leaks through air exhaust port. Replace diaphragms, and any parts that may have been

damaged by fluid exposure.

Reduced Performance Cause: Solution: Supply line restricted (cavitation). Reduce fluid restriction. Quick exhaust seal not seating. Check for particles between seal and port. Replace seal. Check ball(s) not seating. Check O-rings for damage; replace if necessary.

Make sure check balls move freely in sleeves.


6 WARRANTY AND EXCLUSIONS

6.1 TREBOR STANDARD LIMITED WARRANTY https://www.treborintl.com/standard-limited-warranty/

https://www.treborintl.com/standard-limited-warranty/


7 CONTACT INFORMATION 7.1 GENERAL CONTACT INFORMATION

Web: www.treborintl.com Phone Number: (801) 561-0303 Toll Free Number: (800) 669-1303 Fax Number: (801) 565-1510 Email: [email protected] [email protected] Address: Trebor International

8100 South 1300 West West Jordan, Utah 84088 U.S.A.

7.2 TECHNICAL SUPPORT Email: [email protected] Phone Number: (801) 561-0303

7.3 REGIONAL REPRESENTATIVES Web: http://www.treborintl.com/distributors

http://www.treborintl.com/

mailto:[email protected]



http://www.treborintl.com/distributors

Mega 120E Pump Manual

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